When combustion isn’t tightly controlled, energy is lost through excess air, unstable flames, and manual tuning, optimization ensures consistent, efficient fuel use and lower emissions.
The Challenge
The API heater relied on outdated, manually controlled combustion technology, resulting in inconsistent burner performance, inefficient fuel use, and increased safety risk. Uncontrolled operating variables and non‑compliance with B149.3 requirements exposed the operation to regulatory risk and reduced confidence in long‑term reliability.
The Solution
Spartan Controls delivered a single‑vendor combustion optimization solution, combining burner retrofits with FARC advanced combustion control. The upgrade standardized burner performance, stabilized air‑to‑fuel ratios, and eliminated uncontrolled combustion variables.
The solution improved compliance and safety while automating combustion control, removing reliance on manual adjustments. By integrating modern control architecture with upgraded hardware, the heater achieved consistent, optimized combustion across operating conditions.
The solution improved compliance and safety while automating combustion control, removing reliance on manual adjustments. By integrating modern control architecture with upgraded hardware, the heater achieved consistent, optimized combustion across operating conditions.
The Value
The combustion optimization project delivered measurable environmental and financial benefits:
- Up to 15% unit efficiency improvement
- $120,000 in annual fuel savings
- 79% return on investment (ROI)
- 1.3‑year payback on a 30‑year heater asset
- 1,255 tonnes of CO₂e reduced per year
- Emissions reduction equivalent to removing 266 cars per year from the road
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